Method for forming a laser resonator so that optical components of the laser resonator are aligned

ABSTRACT

A laser resonator and method for forming the laser resonator are provided. The method comprises placing a housing for the laser resonator in an alignment fixture, attaching a bond plate to an optical component of the laser resonator, attaching a first end of an alignment arm to the bond plate attached to the optical component, attaching a second end of the alignment arm to the alignment fixture such that the optical component is disposed over the housing, aligning, via the alignment fixture and the alignment arm, the optical component relative to the housing, and bonding the aligned optical component to the housing. The first end of the alignment arm may removed once the aligned optical component is bonded to the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No. 12/122,287, filed May 16, 2008, and entitled “METHOD FOR FORMING A LASER RESONATOR SO THAT OPTICAL COMPONENTS OF THE LASER RESONATOR ARE ALIGNED,” and which is incorporated by reference herein in its entirety for all purposes.

BACKGROUND OF THE INVENTION

The present invention relates to laser resonators. More particularly, the present invention relates to a method for forming a laser resonator so that optical components of the laser resonator are aligned and attached to a laser resonator housing or optical bed without using a mechanical mount for each optical component.

FIG. 1 is a perspective view of a conventional laser resonator 10 with a housing cover removed to illustrate the problems in forming such a conventional laser resonator. As shown in FIG. 1, optical components (e.g., rear mirror 12, wave plate 14 and Risley prism pairs 16 a-16 b, laser pump cavity, lamp, and rod unit 18, q-switch 20, optical parametric oscillator (OPO) mirror 22, OPO crystal 24, and output mirror 26) of a conventional laser resonator 10 are typically mounted to an optical bed 28 using adjustable mechanical mounts 30 a-30 i. Each mechanical mount 30 a-30 i is typically screwed to the optical bed 28 and has one or more adjustable screws to align the respective optical component contained by the mechanical mount relative to an optical path through the laser resonator 10. When the optical components are aligned via the mechanical mounts 30 a-30 i, the optical bed 28 is then attached to a housing (not shown in FIG. 1) for the laser resonator 10. The mechanical mounts 30 a-30 i occupy space on the optical bed 28 and within the laser resonator 10 housing, limiting the miniaturization of the laser resonator 10, increasing component costs, and increasing cost to manufacture. Implementing the laser resonator 10 using an optical bed 28 also increases component and manufacturing costs.

There is therefore a need for a method for forming a laser resonator that overcomes the problems noted above and enables optical components of the laser resonator to be aligned and mounted to a housing or optical bed without employing a mechanical mount for each optical component.

SUMMARY OF THE INVENTION

In accordance with methods consistent with the present invention, a method is provided for forming a laser resonator. The method comprises placing a housing for the laser resonator in an alignment fixture, attaching a bond plate to an optical component of the laser resonator, attaching a first end of an alignment arm to the bond plate attached to the optical component, attaching a second end of the alignment arm to the alignment fixture such that the optical component is disposed over the housing, aligning, via the alignment fixture and the alignment arm, the optical component relative to the housing, and bonding the aligned optical component to the housing.

In one implementation in which the first end of the alignment arm is removeably attached to the bond plate, the first end of the alignment arm is removed from the bond plate after the aligned optical component is bonded to the housing.

In accordance with methods consistent with the present invention, another method is provided for forming a laser resonator. The laser resonator has a plurality of optical components. The method comprises placing a housing for the laser resonator in an alignment fixture, attaching each of the optical components to a respective one of a plurality of bond plates, attaching a first end of each of a plurality of alignment arms to a corresponding one of the bond plates, attaching a second end of each alignment arm to the alignment fixture such that each optical component is disposed over the housing, aligning, via the alignment fixture and the alignment arms, each of the optical components relative to the housing, and bonding each aligned optical component to the housing.

In one implementation, the method further comprises disposing a lasing source within the housing at the start of a predetermined optical path through the housing. Each of the optical components are disposed along the predetermined optical path. In this implementation, the step of aligning comprises turning on the lasing source to cause the lasing source to project a laser beam along the predetermined optical path, and moving each optical component that causes the laser beam to deviate from the predetermined optical path by adjusting, via the alignment fixture, the alignment arm effectively attached to the respective optical component to be moved.

In accordance with articles of manufacture consistent with the present invention, a laser resonator is provided. The laser resonator has a housing, a plurality of optical components, and a plurality of plates. Each plate is affixed to a respective one of the optical components and adapted to be removeably attached to a respective alignment arm of an alignment fixture so that the optical components are aligned with each other to define an optical path through the laser resonator. Each of the optical components are directly bonded to the housing relative to the plate affixed to the respective optical component such that the optical components collectively maintain the optical path through the laser resonator.

Other methods, systems, features, and advantages of the present invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional methods, systems, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the present invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings:

FIG. 1 is a perspective view of a conventional laser resonator with a housing cover removed to illustrate the problems in forming such a conventional laser resonator;

FIGS. 2A-2C collectively show a flow chart depicting a process for forming or manufacturing a laser resonator in accordance with the present invention so that optical components of the laser resonator are aligned relative to an optical path through the laser resonator without employing mechanical mounts for the components;

FIGS. 3A, 3D, 3E and 3G each show a perspective view of an alignment fixture and an exemplary laser resonator disposed in relation to the alignment fixture and manufactured in accordance with the process depicted in FIGS. 2A-2C, where the alignment fixture and the laser resonator are illustrated at various steps of the manufacturing process;

FIG. 3B depicts an enlarged view of one embodiment of the laser resonator in which a recess is etched into a bottom of the laser resonator housing and a first optical component is positioned in the recess to self-align the first optical component to the laser resonator housing;

FIG. 3C is a cross-sectional view of an optical component of the laser resonator that is removeably attached, via a bonding plate, to an alignment arm of the alignment fixture in accordance with the process depicted in FIGS. 2A-2C; and

FIG. 3F is a cross-sectional block diagram view of the optical component in FIG. 3C bonded to a housing of the resonator in accordance with the process depicted in FIGS. 2A-2C.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to an implementation in accordance with methods, systems, and products consistent with the present invention as illustrated in the accompanying drawings.

The flow chart shown in FIGS. 2A-2C depicts a process 200 for forming or manufacturing a laser resonator 300 so that optical components of the laser resonator are aligned relative to an optical path through the laser resonator without employing mechanical mounts for the optical components. Initially, a housing 302 for a laser resonator 300 is placed in an alignment fixture 304 (step 202) as shown in FIG. 3A. The housing 302 is illustrated without a cover and having a rectangular shape. However, the housing 302 may have a square, circular, or other shape without departing from the scope of the present invention. The housing 302 is preferably comprised of a lightweight material, such as Titanium or Aluminum, that may hold its shape under operating conditions and environment in which the resonator 300 is to be used.

In the implementation shown in FIG. 3A, the alignment fixture 304 has a leveling plate 306 upon which the housing 302 is temporarily affixed or secured via screws (not shown in the figures). The leveling plate 306 is leveled relative to a coordinate system 310 defined by a z-axis 310 a, a y-axis 310 b, and a x-axis 310 c of the alignment fixture 304. The leveling plate 306 may be leveled relative to the coordinate system 310 using a plurality of screws 312 a-312 c that adjustable attach the leveling plate 306 to the alignment fixture 304. Thus, the coordinate system 310 corresponds to or reflects a coordinate system of the housing 302.

The alignment fixture 304 has one or more aligner mechanisms 314 a-314 c that may be disposed on either side of the leveling plate 306 or disposed about the housing 302. As discussed in further detail herein, each aligner mechanism 314 a-314 c is attached to one end of a respective alignment arm and an optical component of the laser resonator 300 is effectively attached to another end of the same alignment arm. Each aligner mechanism 314 a-314 c is operatively configured to position or tilt the respective alignment arm and, thus, the optical component attached to another end of the respective alignment arm in at least one axis 314 a, 310 b, or 310 c relative to the housing 302 so that the optical component may be aligned and bonded directly to the housing 302 without employing a mechanical mount for the optical component. Each aligner mechanisms 314 a-314 c may be a 4 axis tilt aligner commercially available from New Focus (a Division of Bookham, Inc.) or another aligner operatively capable of moving an alignment arm in at least one direction along an axis or tilting the alignment arm in at least one axis corresponding to axis 310 a, 310 b, or 310 c of the housing 302.

Returning to FIG. 2A, after the housing 302 is placed in the alignment fixture 304, a first optical component 316 a (e.g., a rear mirror or Porro prism shown in FIG. 3B) is attached directly to the housing 302 (step 204). The first optical component 316 may be attached to the housing 302 using, for example, a UV epoxy or cement such as UV-61. In this implementation, the first optical component 316 a is assumed to have cylindrical shape or other shape that may be self-aligned relative to the housing 302 via a recess 318 (shown best in FIGS. 3A and 3B), such as a “V” groove, that is pre-etched in the bottom 320 (or in a mesa 321 extending from the bottom 320) of the housing 302 to receive and hold the first optical component 316. However, the first optical component 316 a may be aligned and bonded to the housing 302 in the same manner as discussed herein for the remaining optical components 316 b-316 e.

Next, a bond plate 322 a is attached to a next optical component 316 b (e.g., a fold prism or mirror) of the laser resonator 300 (step 206) and a first end 324 of an alignment arm 326 a is removeably attached to the bond plate 322 a (step 208) as illustrated, for example, in FIG. 3C. The bond plate 322 a may be comprised of a lightweight material, such as aluminum or titanium, that is capable of being bonded to the optical component 316 b so that the optical component 316 b may be held in place over the housing 302 when the bond plate 322 a is removeably attached to the alignment arm 326 a. In one implementation, the bond plate 322 a is attached to the next optical component 316 b using an epoxy material such as UV-61.

In one implementation, the bond plate 322 a is removeably attached to the first end 324 of the alignment arm 326 a via a fastener, such as a screw 328. In this implementation, the bond plate 322 a has a threaded recess for receiving and engaging the screw 328 when inserted through an opening in the first end 324 of the alignment arm 326 a.

A second end 330 of the alignment arm 326 a is attached to the alignment fixture 304 or one of the aligner mechanisms (e.g., 314 a) such that the optical component 316 b is disposed over the housing 302 (step 210) as shown, for example, in FIGS. 3C and 3D. When the alignment arm 326 a is attached between the alignment fixture 304 (or the aligner mechanism 314 a) and the bond plate 322 a, the optical component 316 b defines a gap 332 (as shown in FIG. 3F) between the optical component 316 b and the housing 302. As discussed in further detail below, the gap 332 may be adjusted in response to aligning the optical component 316 b by moving or tilting the alignment arm 326 a via the alignment fixture 304 or the respective aligner mechanism 314 a to which the alignment arm 326 a is attached. When alignment of the optical component 316 b is completed in accordance with the present invention, the gap 322 between the optical component 316 b and the housing 302 may have a non-symmetrical thickness.

In one implementation, the second end 330 of the alignment arm 326 a is removeably or pivotally attached to the alignment fixture 304 or the aligner mechanism 314 a (e.g., via screws 331 a or 331 b or other fasteners) so that the alignment arm 326 a may be detached or moved away from the housing 302, enabling the laser resonator 300 to be removed from the alignment fixture 304 after completion of the process 200. Note the process steps of attaching the bond plate 322 a to the optical component 316 b, attaching the bond plate 322 a to the alignment arm 326, and attaching the alignment arm 326 to the alignment fixture 304 or the aligner mechanism 314 a may be completed in any order without departing from the scope of the present invention.

Continuing with FIG. 2A, after the optical component 316 b is effectively attached to the alignment fixture 304 or the aligner mechanism 314 a via the bonding plate 322 a and the alignment arm 326 so that the optical component 316 b is disposed over the housing 302, the optical component 316 b is statically aligned via the alignment fixture 304 or the aligner mechanism 314 a (step 212). In one implementation depicted in FIG. 3D, statically aligning comprises reflecting a laser beam 334 a from a lasing source 336 off of the optical component 316 b, determining whether the reflected laser beam 334 b deviates from a predetermined path (e.g., a path corresponding to a chief ray of the laser beam 334 a incident upon the optical component 316 b), and, in response to determining the reflected laser beam 334 b deviates from the predetermined path, adjusting the optical component 316 b via the aligner mechanism 314 a of the alignment fixture 304 and the alignment arm 326 a that is effectively attached to the optical component 316 b. Although the lasing source 336 is shown external to the laser resonator housing 302 for static alignment of the optical component 316 b, the lasing source 336 for static alignment may be a lasing source 338 (e.g., a pre-assembled lamp pump cavity) that is an internal component of the laser resonator 300 as discussed in further detail below.

Turning to FIG. 2B, a person or machine (not shown in the figures) performing the process 200 may determine whether there are more optical components to be installed in the laser resonator 300 (step 214). Although a machine for performing the process 200 is not shown in the figures, it would be apparent to one of ordinary skill in the art having reviewed the present application that a machine may be implemented using, for example, a computer based robotic system programmed to automatically perform the process 200. Such a machine may include the lasing source 336, have a photo eye for detecting a reflected laser beam 334 b, and robotic arms with fingers adapted to form, manufacturer or assemble the resonator 300 in accordance with the process 200.

As shown in the implementation in FIG. 3E, after the next optical component 316 b is statically aligned to the laser resonator housing 302 as described above and if the optical component 316 b does not require being dynamically aligned with the other optical components 316 c-316 e as further described below, the optical component 316 b may be bonded to the housing as discussed in reference to step 224 of process 200 herein. In the implementation shown in FIG. 3E, the next optical component 316 b is a folding prism that may be bonded after being statically aligned with the laser resonator housing 302 without being dynamically aligned with the other optical components 316 c-316 e. In addition, after the next optical component 316 b is statically aligned and bonded to the housing 302, the alignment arm 326 a may be removed from the bonding plate 322 a that is attached to the optical component 316 b. The alignment arm 326 a and the alignment mechanism 314 a may then be used to install the subsequent or next optical component 316 c as shown in FIG. 3E.

Returning to FIG. 2B, if there are more optical components to be installed in the laser resonator 300 after installing the optical component 316 b, the person or machine may continue processing at step 206. Accordingly, by performing the process 200, each optical component 316 b-316 e that is not self-aligned (or at least each of those optical components 316 c-316 e as shown in FIG. 3E that require dynamic alignment relative to each other) is attached to a respective bond plate 322 b-322 d, each bond plate 322 b-322 d is removeably attached to a first end 324 of a corresponding one of a plurality of alignment arms 326 a-326 c, the second end 330 of each alignment arm 326 a-326 c is removeably attached to a respective aligner mechanism 314 a-314 c of the alignment fixture 304 such that each optical component 316 c-316 e to be dynamically aligned is disposed over the housing 302 as shown in FIG. 3E such that each optical component 316 c-316 e defines a respective gap 332 between the optical component 316 c-316 e and the housing 302. In addition, by performing the process 200 through step 214, each of the optical components 316 a-316 e of the laser resonator 300 is statically aligned relative to the housing 302, either via a self-aligning mechanism such as the pre-etched recess 318 in the housing 302 or via a respective aligner mechanism 314 a-314 c of the alignment fixture 304 adjusting the respective alignment arm 326 a-326 c as discussed herein.

Continuing with FIG. 2B, if there are no more optical components 316 c-316 e to be installed in the laser resonator 300, a lasing source 338 (e.g., a pre-assembled lamp pump cavity) is attached or installed within the housing 302 at the start of a predetermined optical path 340 through the housing 302 (step 216). As shown in FIG. 3E, each of the optical components 316 a-316 e is disposed along the predetermined optical path 340.

Note the lasing source 338 may be attached or installed in alternate sequence with the optical components 316 a-316 e. For example, when the lasing source 338 is a laser lamp pump cavity requiring a rear mirror as the first optical component, the lasing source 338 may be attached or installed after the first optical component 316 a and before the remaining optical components 316 c in sequence with where the components 316 a-316 e and 338 are in the predetermined optical path 340. In addition, the resonator 300 may include other components, such as electrical power supply, a Q-switch, a polarizer, and return cables 346 a and 346 b for the lasing source 338, which are not described in detail to avoid obscuring the present invention.

After the lasing source 338 is attached or installed in the housing 302, the lasing source 338 is turned on, causing the lasing source 338 to emit a laser beam 342 along the predetermined optical path 340 for output through an exit pupil 344 of the laser resonator 300 (step 218). Each optical component 316 c-316 e that causes the laser beam 342 to deviate from the predetermined optical path 340 is moved or tilted by adjusting (via the respective aligner mechanism 314 a-314 c of the alignment fixture 304) the alignment arm 326 a-326 c that is effectively attached to the respective optical component 316 c-316 e to be moved (step 220).

Turning to FIG. 2C, the person or machine performing the process 200 next determines whether all the optical components 316 c-316 e have collectively been dynamically aligned (step 222). In one implementation, the optical components 316 c-316 e may be deemed dynamically aligned by determining whether the laser beam 342 existing the exit pupil 344 is aligned with a respective axis 310 a, 310 b, or 310 c of the coordinate system 310 of the housing, and/or by measuring the output energy of the laser beam 342 to ensure the output energy is within a predetermined range that reflects the optical components 316 a-316 e are effectively in alignment with the predetermined optical path 340.

If the optical components 316 c-316 e are not dynamically aligned, processing continues at step 220 to re-adjust, via the respective aligner mechanism 314 a-314 c, the optical components 316 c-316 e that may be causing the laser beam 342 to deviate from the predetermined optical path 340.

If the optical components 316 c-316 e are dynamically aligned, each optical component 316 c-316 e is then directly bonded to the housing 302 (step 224). As shown in FIG. 3F, each optical component 316 c-316 e may be bonded to the housing 302 using a epoxy, cement, or other bonding material 348 that sets quickly so that the alignment of the respective optical component 316 c-316 e to the housing 302 may be maintained when the alignment arm 326 a-326 c is removed from the bond plate 322 b-322 d attached to the respective optical component 316 c-316 e. The bonding material 348 may be, for example, a UV activated epoxy, such as UV-61. In the implementation shown in FIG. 3E, at least a portion of the gap 332 between the respective optical component 316 c-316 e and the housing 302 is filled with the bonding material 348 such that the optical component 316 c-316 e remains in fixed alignment with the housing 302 after the first end 324 of the alignment arm 314 a-214 c is removed from the bond plate 322 b-322 d.

After each optical component 316 a-316 e is bonded to the housing 302, the respective alignment arm 326 a-326 c is removed or detached from the bonding plate 322 a-322 d to which the respective optical component 316 a-316 e is attached. (step 226). In the implementation shown in FIG. 3F, the fastener or screw 328 attaching a respective alignment arm 326 a-326 c is removed from the respective bonding plate 322 a-322 d.

In one implementation, each alignment arm 326 a-326 c is also removed or detached from the alignment fixture 304 or the respective aligner mechanism 314 a-314 c (step 328) as shown in FIG. 3G and the laser resonator 300 is removed from the alignment fixture (step 230) before ending processing. In the implementation in which an alignment arm 326 a-326 c is pivotally attached to the aligner mechanism 314 a-314 c, step 228 of the process 200 may comprise pivoting the alignment arm 326 a-326 c away from the housing 302 so that the resonator 300 may be removed from the fixture 304. In addition, a cover (not shown in the figures) may be attached to the open end of the laser resonator 300 to seal the laser components 316 a-316 e in the laser resonator 300.

Thus, since the optical components 316 a-316 e of the resonator 300 are directly bonded to the housing 302 in accordance with the present invention, the resonator 300 may be formed or manufactured without employing a separate optical bed or mechanical mounts for aligning and attaching the optical components to the optical bed. As a result, implementing the present invention for forming a laser resonator, significantly decreases component costs and manufacturing costs as well as enables the laser resonator to be miniaturized to a size smaller than conventional laser resonators.

While various embodiments of the present invention have been described, it will be apparent to those of skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents. 

What is claimed is:
 1. A method for forming a laser resonator, comprising: placing a housing for the laser resonator in an alignment fixture; attaching a bond plate to an optical component of the laser resonator; attaching a first end of an alignment arm to the bond plate attached to the optical component; attaching a second end of the alignment arm to the alignment fixture such that the optical component is disposed over the housing; aligning, via the alignment fixture and the alignment arm, the optical component relative to the housing; and bonding the aligned optical component to the housing.
 2. The method of claim 1, wherein the first end of the alignment arm is removeably attached to the bond plate and the method further comprises removing the first end of the alignment arm from the bond plate after the aligned optical component is bonded to the housing.
 3. The method of claim 2, wherein the bond plate is bonded to the optical component using an epoxy material.
 4. The method of claim 3, wherein the bond plate is removeably attached to the first end of the alignment arm via a fastener.
 5. The method of claim 1, wherein, when the alignment arm is attached between the alignment fixture and the bond plate, the optical component defines a gap between the optical component and the housing.
 6. The method of claim 5, wherein: the first end of the alignment arm is removeably attached to the first end of the alignment arm, and the step of bonding comprises filling at least a portion of the gap between the optical component and the housing with a bonding material such that the optical component remains in fixed alignment with the housing after the first end of the alignment arm is removed from the bond plate.
 7. The method of claim 6, wherein the bonding material is a UV epoxy.
 8. The method of claim 1, wherein the alignment fixture is operatively configured to selectively move the alignment arm such that the optical component is moved in at least one direction relative to the housing before the aligned optical component is bonded to the housing.
 9. A method for forming a laser resonator, the laser resonator having a plurality of optical components, the method comprising: placing a housing for the laser resonator in an alignment fixture; attaching each of the optical components to a respective one of a plurality of bond plates; attaching each bond plate is attached to a first end of a corresponding one of a plurality of alignment arms; attaching a second end of each alignment arm to the alignment fixture such that each optical component is disposed over the housing; aligning, via the alignment fixture and the alignment arms, each of the optical components relative to the housing; and bonding each aligned optical component to the housing.
 10. The method of claim 9, wherein the step of aligning comprises reflecting a laser beam from a lasing source off of a first optical component, determining whether the reflected laser beam deviates from a predetermined path, and, in response to determining the reflected laser beam deviates from the predetermined path, adjusting the first optical component via the alignment fixture and the alignment arm effectively attached to the first optical component.
 11. The method of claim 9, further comprising disposing a lasing source within the housing at the start of a predetermined optical path through the housing, wherein each of the optical components are disposed along the predetermined optical path, and the step of aligning comprises: turning on the lasing source to cause the lasing source to emit a laser beam along the predetermined optical path; and moving each optical component that causes the laser beam to deviate from the predetermined optical path by adjusting, via the alignment fixture, the alignment arm effectively attached to the respective optical component to be moved.
 12. The method of claim 11, wherein each bond plate is removeably attached to a first end of a corresponding one of a plurality of alignment arms and the method further comprises removing each bond plate from the first end of the corresponding one of the alignment arms after the optical components are aligned and bonded to the housing.
 13. The method of claim 9, wherein each optical component is bonded to a respective one of the bond plates using an epoxy material.
 14. The method of claim 9, wherein each bond plate is removeably attached to the first end of a corresponding one of the alignment arms via a respective fastener.
 15. The method of claim 14, wherein the step of bonding comprises: filling at least a portion of a respective gap between each optical component and the housing with a bonding material such that each optical component remains in fixed alignment relative to the housing.
 16. The method of claim 15, further comprising, after bonding a respective optical component to the housing, detaching the alignment arm from the base plate to which the respective optical component is attached.
 17. The method of claim 9, wherein the each optical component is bonding to the housing a UV epoxy.
 18. The method of claim 9, wherein the alignment fixture has a plurality of aligner mechanisms, each of the aligner mechanisms is attached to a respective one of the alignment arms, and each of the aligner mechanisms is adapted to selectively tilt the alignment arm attached to the aligner relative to a plurality of axis associated with the housing. 